Abstract: A process for forming a cushion layer of a preselected thickness on an inside of a prosthetic liner body is provided and includes the steps of introducing the liner body into a mold cavity; disposing a sufficient amount of cushioning material into the inside of the liner and directing a mandrel into the inside of the liner body. The driving action of the mandrel causes the cushioning material to be dispersed between the mandrel and the liner body, thereby forming the cushioning layer of preselected thickness.

Abstract: A number of different methods for applying a layer of cushioning material to a surface of an article are provided, whereby the thickness of the cushion layer can be controlled to a high degree of precision and the profile of the cushion layer can also be controlled and varied depending upon the application.

Abstract: An improved cushioned liner (i.e., prosthetic liner) for covering a residual limb of an amputee is provided. According to one embodiment, the cushioned liner includes a sock-shaped fabric body member formed of at least two fabric pieces. One of the fabric pieces is a distal end piece that is attached to at least one other fabric piece along a circumferential edge of the distal end piece. The distal end piece is free of a transverse seam that extends across the distal end piece. The cushioned liner also includes a cushion layer disposed on at least one side of the sock-shaped fabric member. In another embodiment, a liner body having the above construction is provided and is adapted to receive cushioning material to form the cushioned liner.